BUILDING

MAINTENANCE
UNITS

AGENDA
Session 1 Session 2
Introduction to Building Design principles of BMUs
Maintenance Units (BMUs)

Session 3 Session 4
Safety features and regulatory Temporary Gondola design
design requirements of BMUs for construction use

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PROJECT EXAMPLE:
CTF TIANJIN

○ 530 metres
○ Outward sloping façade
○ Limited space at roof

1 BMU
180 m

○ 1 BMU at top

○ 4 BMUs at L71 with

complete coverage
4 BMUs

○ Splits tower into two

340 m

smaller towers

○ Reduced travel times

○ Reduced BMU quantity

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○ Roof BMU (red) does not need to access below L71

○ How to get glass from ground to top?

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SESSION 3

Safety features and regulatory design requirements

TODAY’S AGENDA
1. Design standards

2. Wheel loads

3. Safety features

4. Design life

5. Inspection, examination and test

6. Testing details

7. Training

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 INTERNATIONAL STANDARDS

○ Project location determines standard

○ EN 1808 often required in China and HK specifications
○ Consultant may add additional standards

HONG KONG STANDARDS

For suppliers, building For RPE (registered

management, operators professional engineers)

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 GB

National Standard
Of the People’s Republic of
China
_________________________

GB 19154-2003

Permanently installed
suspended access equipment

○ Based on and similar to EN1808

○ Less detailed than EN1808 (e.g. restraints)
○ Higher wind loads (20 m/s vs 31 m/s)
○ Higher stability requirements (3:1 vs 2:1)

TODAY’S AGENDA
1. Design standards

2. Wheel loads

3. Safety features

4. Design life

5. Inspection, examination and test

6. Testing details

7. Training

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WHEEL LOADS

DEFINING THE LOADS

○ 4 wheels
○ Vertical and horizontal
loads
○ Loads vary depending
on jib direction (0-90°)

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 TYPICAL WHEEL LOAD TABLE
○ BMU supplier provides this table to the client for roof design
○ Is it factored? Do the building engineers need to add extra factors?

Wost case
x4?

WHEEL LOAD CALCULATION

SWL: 240kg for 2 persons plus tools (Safe working load)

Cradle: 130kg for 2m long
Wire ropes: 200kg for 200m x 4 ropes x 0.25 kg/m (Φ8mm)
TSL: 570kg (Total suspended load)

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 GHU

Materials: 400kg inc GHU (1000kg maximum by EN1808)

Wire rope: 50kg for 200m x 0.25 kg/m (Φ8mm)
TSHL: 450kg (Total suspended hoist load)

Mo (Mass outboard): Jib + Crossbar

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Mi (Mass inboard): Mast + baseframe + hoist + counterweight

Add enough counterweight so there is always static downloads

Wind loads: 31 m/s HK, 20 m/s EN1808

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 ○ Sum moments and forces to get wheel loads
○ Static operating case is unfactored
○ Out of service case is unfactored
○ What are the factors on Load Case 1 and Stability?

(Jib retracted, no cradle)

EN1808 LOAD CASE 1

○ To account for dynamic effects, dasically add 25% to static

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EN1808 STABILITY
○ Theoretical loads. HK code uses factor of 3 instead of 2.
○ Adding a further factor of 4 for roof design not neccesary

○ What additional factors should be applied to the building?

1.25x static

2x TSL, 1.4x TSHL, 1.25x Mo

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PARTIAL SAFETY FACTORS FOR EUROCODES
Load Case Factor yf
Load case 1 (EN1808) 1.6
Out of service (EN1808) 1.4
Working stability (EN1808) 1.1 <4

Sd = Sk · yf
Sd = Design value of the load (Sd from Eurocodes)
Sk = Characteristic loads (inc. dynamic factors)
yf = Partial safety factor on the loads

For structural engineers using the limit state method as per Eurocodes
EC1 and EC3, it is recommended that the following factors be applied by
the as a minimum to the load cases for the purpose of identifying the design
loads for the superstructure (building). However it is the responsibility of
the structural engineer to ensure imposed loads for the SAE are
accounted for in the superstructure design.

○ Request the extra information from the supplier

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FINAL NOTE: UPLIFT
○ BMUs generally counterweighted to ensure downloads
○ Stability case may still show uplift
○ Track and support design must consider the uplift

TODAY’S AGENDA
1. Design standards

2. Wheel loads

3. Safety features

4. Design life

5. Inspection, examination and test

6. Testing details

7. Training

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SAFETY FEATURES

PROTECTION FROM WIRE ROPE FAILURE

○ 2 ropes each side

○ 12:1 factor of safety (EN1808)
○ Harness anchor for roof- mounted hoists
○ Consider rescue plan after fall-arrest

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PROTECTION FROM WIRE ROPE FAILURE
○ Platform mounted hoists need separate lifeline
○ Permanent suspended platform: can anchor to roof rig
○ Temporary suspended platform: must anchor to roof structure

PROTECTION FROM UNBALANCED CRADLES

Platform mounted hoists
○ Level sensor to prevent more than 14° incline
○ Operators then can manually adjust each motor
○ EN1808 requirement

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 Uneven layering of ropes

PROTECTION FROM UNBALANCED CRADLES

Roof mounted hoists
○ Drums with a single layer of rope not affected
○ Single layer not suitable for tall buildings
○ Drums with multiple rope layers can have issues

Uneven layering of ropes

PROTECTION FROM UNBALANCED CRADLES

Roof mounted hoists
○ Drums with a single layer of rope not affected
○ Single layer not suitable for tall buildings
○ Drums with multiple rope layers can have issues

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 Alignment holes

Optical sensor

PROTECTION FROM UNBALANCED CRADLES

○ Layering sensor for roof mounted hoists
○ Ensures even layering

Lower trip bar Upper trip bar

PROTECTION FROM UNBALANCED CRADLES

○ Prevent lowering or raising onto façade features
○ Prevent imbalance, protect facade

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PROTECTION FROM OVERLOAD
○ Sensors in cradle
○ Current monitoring in hoist motor

PROTECTION FROM OVERLOAD

○ Restraint trip sensors

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PROTECTION FROM OVERLOAD
○ Lifting limit switch
○ Ultimate lifting limit switch
○ Same for materials hoist

PROTECTION FROM UNDERLOAD

○ Avoid excess / slack rope build up in system
○ Optical sensor

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Primary
brake

PROTECTION FROM HOIST FAILURE

○ Example: drive motor failure
○ Secondary brake required (primary = motor brake)
○ 2 options for implementation

SECONDARY BRAKE: OPTION 1

○ Overspeed governor example from an elevator

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 Governor

SECONDARY BRAKE: OPTION 1

○ Overspeed governor Flyweight

SECONDARY BRAKE: OPTION 1

○ Testing video from BMU hoist

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SECONDARY BRAKE: OPTION 2
○ Fail-to-safe electrical monitoring of speed
○ Fail-to-safe mechanically applied, hydraulic release brake
○ Hydraulic power pack has manual mode for emergencies

MANUAL LOWERING OF HOIST

1. PRESS E-STOP

2. HAND PUMP LEVER

3. HYDRAULIC BRAKE
MANUAL RELEASE
BUTTON

4. MOTOR BRAKE
RELEASE HANDLE Lowering speed controlled by capacitor bank

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ELECTRICAL INTERLOCKS
● Key lock operation
● Cradle at top limit for motions
○ Where possible
● Jib retracted during long travel
● Design benefits, cost reduction

TODAY’S AGENDA
1. Design standards

2. Wheel loads

3. Safety features

4. Design life

5. Inspection, examination and test

6. Testing details

7. Training

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BREAK: 10 MINUTES

HOW LONG WILL IT LAST?

● BMUs are designed for the life of the building

● Regular maintenance in line with manufacturer

requirements will ensure long life
● Mechanical and electrical parts will need to be
replaced
● Structure is galvanised,
painted, but requires
monitoring

● Warranty generally
12 months

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REPLACEMENT BMUs
● More common on old buildings
● Upgrade safety
● Reduce maintenance downtime
● Ensure loads ≤ old BMU
○ Site measurement
○ Load cells

REPLACEMENT BMU: EXAMPLE

● Wing On Centre Sheung Wan
● ~30 years old
● Increase safety and reduce maintenance

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 REPLACEMENT BMU: EXAMPLE

● Step 1: Erect temporary boom

● Boom parts carried in freight elevator
● Smaller boom can be needed to lift bigger boom

REPLACEMENT BMU: EXAMPLE

● Step 2: Remove old BMU

● Step 3: Install new BMU
(& track)

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REPLACEMENT BMU: EXAMPLE

TODAY’S AGENDA
1. Design standards

2. Wheel loads

3. Safety features

4. Design life

5. Inspection, examination and test

6. Testing details

7. Training

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 INSPECTION, EXAMINATION AND TEST

● Inspection on day of use

● Inspection within 7 days of use
● Examination within 6 months of use
● Testing within 12 months of use

Only required when BMU is in use

WHO IS RESPONSIBLE?

“The Owner”. This can include:

● The lessee or hirer

● Any overseer, foreman, agent or person in
charge
● contractor responsible for the
construction site

● Code of practice has special legal status

● Failure to comply is not an offence, but
could be considered in court

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WHO CAN INSPECT?
A “Competent Person”

● Appointed by the owner to ensure that the duty is

carried out
● By reason of substantial training and practical
experience, competent to perform the duty

WHO CAN EXAMINE AND TEST?

A “Competent Examiner”
● Appointed by the owner to ensure thorough
examination or load test is carried out
● A registered professional engineer within a relevant
discipline (mechanical or marine engineer)
● By virtue of his previous experience, competent to
carry out such thorough examination or load test

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 INSPECTION: DAILY
● By a competent person
● Inspect suspension ropes
● Inspect safety ropes
● No bolts loose or removed
● All connections sound

INSPECTION: 7 DAYS
● By a competent person
● Check for abnormal wear, corrosion, noise,
misalignment
● Check hoist, ropes, platform, trolley
● Functional test of controls, limit switches,
safety features

● Record and repair defects

● Retest and examine after repairs
● Statement issued in approved form (Form 1)

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THOROUGH EXAMINATION: 6 MONTHS

● By a competent examiner
● Detect significant defects of critical parts
● All parts checked
● Full length of wire rope
● Functional test of controls, limit switches,
safety features

● Record and repair defects

● Retest and examine after repairs
● Statement issued in approved form (Form 2)

TEST AND THOROUGH EXAMINATION:

12 MONTHS

● By a competent examiner
● Examination as per 6 month requirements
● Load test
● Load test also needed following:
○ Substantial repair
○ Re-erection (e.g. moving a davit)
○ Adjustments or modifications

● Record and repair defects

● Retest and examine after repairs
● Certificate issued in approved form (Form 3)

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TODAY’S AGENDA
1. Design standards

2. Wheel loads

3. Safety features

4. Design life

5. Inspection, examination and test

6. Testing details

7. Training

TESTING DETAILS

Site tests
● Proof load test
● Overload device function test
● Operational test

Factory tests
● Similar to above, following EN1808

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 PROOF LOAD TEST

● By a competent examiner
● Static type test
● Check of structure, not functions
● 150% of cradle SWL
○ (e.g. 375kg for 250kg SWL)
● 125% of materials hoist SWL
○ Non-man carrying device
○ Materials hoist covered by “lifting
appliances regulation”

OVERLOAD DEVICE FUNCTION TEST

● Check the cradle cannot
become overloaded
during operation
● By a competent
examiner
● To manufacturer’s
recommendations

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OPERATIONAL TEST
● By a competent examiner
● 100% SWL
● 100% materials SWL
● Check all functions of BMU

ADDITIONAL TESTING
Client may request:
● Demonstrate all areas of facade accessible
● Maximum reach
● Complex drops, recesses
○ Pull-in restraints, telescopic cradle, etc

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 TODAY’S AGENDA
1. Design standards

2. Wheel loads

3. Safety features

4. Design life

5. Inspection, examination and test

6. Testing details

7. Training

TRAINING
● Not just window washers
● CoP requires every person to be trained and
certified
● Construction Industry Council (CIC) holds
training courses with certification
● Not project specific
● We recommend refresher training every 2
years
● At owner request, suppliers hold own training
course for each building

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 FURTHER READING

○ EN 1808 is easy to follow and contains example calculations

Q&A
Any questions?

Next session: tomorrow, 7pm with Peter Chan

peter.ransom@gmail.com

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